CABLES 11.

CHAPTER-11

CABLES

SNO.
1. TYPE OF CABLES & RATING 2. SELECTION OF CABLE 3. GUIDELINE FOR UNDERGROUND CABLE LAYING 4. JOINTING AND TERMINATION OF CABLES 5. COMPARISON BETWEEN OVERHEAD LINE AND CABLE

CABLES 11.2

TYPE OF CABLES AND RATINGS A cable means a length of insulated single conductor (solid or stranded) or of two or more such conductors, each ro!ided with its insulation which are laid together. Such insulated conductor or conductors ma" or ma" not be ro!ided with an o!erall mechanical rotecti!e co!ering. #n ower s"stem , cables fall into two categories$ 1) Power cables 2) Con rol cables.

%ower cables are designed to transmit electric ower and come in a wide range of !oltage ratings. &hese cables are called ' Low &ension Cables( u to 1))) !olt grade, *igh &ension cables( abo!e 1))) !olt grade and u to ++))) !olt grade and 'E,tra *igh &ension Cables( abo!e ++)) !olt grade. -e ending on the number of cores, these cables are single. core, twin core, three core, three.and.half.core, and four.core. %ower cables !ar" in design according to the ser!ice the" are intended for and according to their thermal and electrical characteristics. Control cables are designed for o eration in alternating current circuits with !oltages u to /)) !olt or in direct current circuits with !oltages u to 1))) !olt. &hese cables ser!e as the means for inter connection of all the rotecti!e, indicating, metering and remote 0 automatic control de!ices installed throughout ower stations and !arious sub.stations. &he t" e of a articular cable to be used at a articular location is determined b" the mechanical considerations and the !oltage at which it is re1uired to o erate. 2suall" the o erating !oltage decides the t" e of insulation and cables are laced in !arious categories de ending u on the !oltage for which the" are designed. A cable ma" ha!e the following arts. 1. #. %. *. /. 0. Con!"c or Ins"la $on S&$el!$n' (or 1) an! #) Inner + S&ea & ,Co--on + co.er$n') Ar-o"r$n' O" er + S&ea &

Conductor and insulation are the essential arts of a cable. Armouring is o tional as er re1uirement. Shielding (or screening) is generall" used in high.tension cables (Abo!e 134 and u to ++34) Based u on current carr"ing ca acit" and !oltage le!el, t" e of conductors and insulations are selected. Change in the t" e of conductor, insulation, inner sheath and armouring ma5es the t" e of cable different. *ere is some brief descri tion of different

CABLES 11.+

t" es of cables using !arious t" es of conductors, insulations, inner sheaths, armouring etc. 1. TYPE OF COND1CTOR 1SED2 Co er and aluminium are used for ma5ing conductors of the cable. Co er is in!ariabl" used in fle,ible cables. Aluminium (Al) is +./ times lighter than co er (Cu), its resistance is 1.6/ times that of co er (Cu) for same length and cross.section of conductor at 2)7C. 8wing to abundance of Al, its low cost and lighter weight, the ma9orit" of ower cables are at resent manufactured with Al conductors s eciall" for higher ratings. Conductor ma" be solid or stranded. #. N13BER OF CORES 1SED2 A cable conductor ma" be single core or multi.core as er the re1uirement. A core com rises the conductor which ma" consists of one or more wires stranded together and also the conductor insulation. &he stranding is necessar" to secure fle,ibilit". +. TYPE OF INS1LATION 1SED$

8 erating !oltage of the cable is the main factor for selecting insulating material for its conductor. #n general an insulating material to be used in a cable must ha!e the following main ro erties$ 1. 2. +. ;. /. 6. *igh dielectric strength *igh insulation resistance :ood mechanical ro erties i.e elasticit" and tenacit" #mmune to attac5s b" acids and al5alis <ust be non.h"grosco ic or if h"grosco ic must be enclosed in a water tight co!ering. =ot too costl".

<aterials used for cable insulation since beginning are$

a)

I3PREGNATED PAPER $ Chemicall" ul ed a er from wood chi ings in ta e form is im regnated in s ecific mineral oil. Some resin is also added to it to lower its !iscosit" and to im ro!e im regnating 1ualities of the oil. -ielectric strength of im regnated a er > 2).+) 34?mm

CABLES 11.;

-ielectric Constant

>

+.6

Since a er is h"grosco ic, it is essential to rotect such cables from the ossible ingress of moisture. @or, it is enclosed in a moisture roof sheath of lead (mostl") or aluminium (in s ecial cases) b) 41LCANISED INDIA R1BBER ,4.I.R) &hese are not used in large siAes but are used in com arati!el" small wiring such as lighting and ower installations. -ielectric strength of 4.#.B -ielectric constant of 4.#.B > > 1).2) 34?mm 2./

%a er cables are su erior than 4.#.B cables. c) 4ARNISHED CA3BRIC 2 &his is a cotton cloth im regnated and coated with !arnish which is a ure linseed oil with etroleum bitumen. &he cambric is la ed on the conductor in the form of a ta e. As this insulating material is h"grosco ic, it has lead .Csheath o!er it. -ielectric strength -ielectric constant !) > > ; 34?mm 2./ C +.D

POLY4INYL CHLORIDE ,P.4.C) 2 #t has re laced most of abo!e insulating materials. =ow a da"s %4C is being used e,tensi!el". #t is s"nthetic material obtained from acet"lene. %4C is inert to o,"gen, oAone and to man" acids and al5alis. #t is flame retarding itself. En!ironmentall" it is referable to rubber.

e)

SILICON-R1BBER 2 #t gi!es greater thermal stabilit" o!er the great range of C E)7C to 2/)7C, because of larger siAe and structure of silicon molecules. #ts resistance to oils, to oAone, and to water are fairl" good but to strong acid and al5alis, it is oor. -ielectric strength of silicon rubber -ielectric constant of silicon rubber > > 12.+)34?mm +.6.E.)

f)

CROSS LIN5ED POLYETHYLENE PO6R CABLES2

CABLES 11./

Abo!e +.+34, for high tension cables FL%E insulation is selected because of im ortant ro erties and ad!antages of FL%E o!er %4C as under$ a) b) c) d) e) f) *igher continuous current carr"ing ca acit" *igher short C circuit current ca acit" *igher emergenc" load carr"ing ca acit" Lower dielectric loss Lower charging currents Lower weight and smaller bending radii ma5ing la"ing and installation easier.

FL%E cables normall" use circular stranded Aluminium wires for conductor, FL%E insulation a lied o!er conductor b" e,trusion rocess, shielding?screening o!er conductor as well as FL%E insulation, inner sheath (common. co!ering) of wra ed lastic ta es or e,truded %4C, armouring of flat steel wires (Stri s) or round steel wires and finall" tough outer sheat of %4C com ound e,truded o!er the armouring.
82&EB S*EA&* AB<82B &A%E GBA%#=:

@#LLEB C8BE #-E=&#@#CA&#8= &A%E? Cu &A%E SCBEE=#=: EF&B2-E- SE<#.C8=-2C&#=: C8BE S*#EL-#=: FL%E #=S2LA&#8= EF&B2-E- SE<#.C8=-2C&#=: C8=-2C&8B S*#EL-#=: AL2<#=#2< C8=-2C&8B

')

TYPE OF INNER SHEATH 1SED2

Cable sheaths are necessar" rimaril" because the insulation must be rotected against an" ingress of moisture. A secondar" ur ose is to rotect the insulation from attac5 b" the surrounding atmos here. &he sheath shall be a lied b" e,trusion o!er the insulation in case of single core cables and o!er the laid u cores in other cases. Single core %4C insulated cables will not ha!e an" inner sheath. #n case of %4C insulated multi core cables, the laid u cores are surrounded b" an inner sheath of an" of the following t" es$

CABLES 11.6

a) b) c)

E,truded %4C E,truded 2n!ulcanised rubber Gra ing of %4C ta es.

Lead and aluminium ae used as sheath for im regnated a er insulated cables u to 6.634. Aluminium is used u to 11) 34 such cables. &) TYPE OF AR3O1RING 1SED2

-e ending u on the t" e of a lication used, cables ma" be armoured or unarmoured since all the insulating materials used in the construction of cables, are mechanicall" wea5, Some form of rotection against mechanical in9ur" is re1uired. &his ur ose is sol!ed b" means of armouring. Armouring is a lied o!er the core insulation in case of single core cables and o!er the inner sheath in case of multi core cables. Ghere the calculated diameter below armouring does not e,ceed 1+mm, the armour shall consist of gal!aniAed round steel wire. &he armoure of cables ha!ing calculated diameter below armouring greater than 1+mm shall consist of either gal!aniAed round steel wire or gal!aniAed steel stri s. #n case of single core cables the armouring shall be of non.magnetic material if cable is used in a.c s"stem. #f the single core cables are to be used in d.c s"stem, the cable can be armoured with steel wires. $) TYPE OF O1TER SHEATH 1SED2

All cables whether armoured or not, ha!e an e,ternal co!ering or outer sheath against corrosion moisture and damage. A tough outer sheath of suitable grade of %4C com ound is e,truded o!er the armouring in case of armoured cables or inner sheath in case of unarmoured cables. &his is alwa"s blac5 in colour for best resistance to outdoor e, osure. &he beha!iour of electric cables in resence of fire has been a matter of concern. Although %4C itself is flame retarding , it does roduce highl" to,ic and corrosi!e fumes in the e!ent of fire. @ume to,icit" is im ortant as it causes serious conse1uences for human safet", suffocation, into,ication and anic due to reduced !isibilit" articularl" in closed and crowded laces. #n !iew of abo!e suitable %4C @LA<E BE&AB-A=& L8G S<83E A=- L8G *AL8:E= (@BLS) com ound has been de!elo ed b" <?s.%*EL%S -8-:E #=&EB=A&#8=AL C8B%8BA&#8=, 2SA with the following ro erties.

CABLES 11.H

a) b) c)

Low?<inimum smo5e emission 4er" low to,ic and corrosi!e fumes emission and @ire retarding ro erties.

8uter sheath of cable is made u of this @BLS %4C com ound. 8n the basis of abo!e described t" es of cable construction, s ecial ur ose cables e.g telecommunication cables (with or without 9ell" C filled), com uter cables, signal cables, cable for submersible um motors etc, can be manufactured with minor changes in the construction. CORE IDENTIFICATION2 Cores are identified b" different colouring of %4C insulation as described below$ a) b) c) d) e) Bed, Blac5, Iellow or Blue Bed and Blac5 Bed, "ellow and Blue Bed,Iellow,Blue 0Blac5 (=eutral) Bed,"ellow,blue,blac5 and light gre". g) 6 core 0 abo!e $ &wo ad9acent cores (counting and direction core) in each la"er, blue and "ellow and the remaining cores Light :re". COND1CTOR TYPES2 re rm sm . . . circular solid conductor Circular stranded conductor Sector sha ed, stranded conductor Single core 2 core + core + J core ; core $ $ $ $ $

TYPE DESIGNATION 2 A $ Aluminium conductor, when first letter of t" e designation where!er t" e designation does not contain KAL in the beginning, then cable is with co er conductor. Ghen at first or second lace in t" e designation, it stands for insulation. Steel round wire armour Steel flat stri armour

I G @

$ $ $

CABLES 11.D

GG @@ I

$ $ $

Steel double round wire armour Steel double flat stri armour %4C outer sheath, when at last lace in t" e designation it stands for sheath.

E7A3PLES2 1. AYFY % core 8 /9 s:.-- s- 11994 'ra!e2

#t shall be read as Aluminium Conductor, %4C insulated, flat steel stri armoured, %4C o!erall sheathed, + core cable, conductor siAe /) s1.mm stranded section, 11))4 grade. #. YY %; Core 8 1./ S:.-- re 1199 4ol 'ra!e2

#t shall be read as circular solid co er conductor, 1./ s1.mm, %4C insulated, %4C sheathed unarmoured +H core cable, 11))4 grade. C1RRENT RATINGS2 Based on #S$ +E61 %art.## and %art.4, the curent ratings for %4C insulated light dut" cables are based on normal conditions of installation described below$ <a,imum conductor tem erature Ambient tem erature :round tem erature &hermal Besisti!it" of soil &hermal Besisti!it" of %4C -e th of la"ing direct in ground $ $ $ $ $ $ H)7C (6/7C for a er #nsulated cables) ;)7C +)7C 1/)7C cm?watt 6/)7C cm?watt As er !oltage grade

@or the !arious rating factors a licable for different conditions of installation #S$+E61 %art.## and %art.4 are a licable. #n short , rating factors shall be a lied, if there is an" de!iation from abo!e assumed standard conditions or if the cables are laid in grou s. SHORT CIRC1IT RATINGS2 &hese are defined as those lasting for a fraction of second and caused due to brea5 down in the electrical s"stem. &hese are based on the assum tion

CABLES 11.E

that all the heat generated during the short circuit is absorbed b" the conductor and there is no e,ternal loss. &hese ratings are su assum tions$ a) b) c) lied b" the manufacturer on the basis of following

Conductor tem . rior to short circuit > H)7C @or %4C insulated cables. (6/7C @or a er insulated cables ) . <a,imum ermissible tem erature of conductor during short circuit > 16)7C -uration of short circuit > one second.

@or an" other duration 't( second, !alue gi!en b" the manufacturer is to be di!ided b" Mt. GENERAL RATINGS OF CABLES 1SED IN FERTILISER CO3PLE7. 1. PO6ER CABLES2

Single core, 2.core, +.core, +1?2.core and ;.core armoured or unarmoured, @BLS or FL%E, %4C insulated cables of the siAes 1./ s1.mm, 2./ s1.mm, ; s1.mm, 6 s1.mm, 1) s1.mm, 16 s1.mm, 2/ s1.mm, +/ s1.mm, /) s1.mm, H) s1.mm, E/ s1.mm, 12) s1.mm, 1/) s1.mm, 1D/ s1.mm 2;) s1.mm, +)) s1.mm and ;)) s1.mm. 8ut of abo!e, FL%E *.& cables (+.+34 0 1134 grade) ha!e been used in four siAes i.e 1/) s1.mm, 1D/ s1.mm 2;) s1.mm and +)) s1.mm. *owe!er manufacturing range for 1.134 single core ower cables is easil" a!ailable in the mar5et from 1./ s1.mm to 1))) s1.mm. <ulti core cables are a!ailable u to 6+) s1.mm . #. CONTROL CABLES2

Control cables with co er conductor, 1.134 grade, siAe 1./ s1.mm and 2./ s1.mm, u to 61 cores are within the manufacturing range. *owe!er, in , control cables u to 2; cores ha!e been used. SELECTION OF CABLES FOR PO6R INSTALLATIONS. #t is 1uite im erati!e that detailed cable lanning needs to be made, ta5ing full consideration of the !arious o erating factors, s"stem arameters, earthing, en!ironmental conditions, resent and future load atterns and ca acities etc, determining the most suitable and economic cable siAes in an" ower installation. @ollowing are some of the arameters which should be e,amined before the selection is made$

CABLES 11.1)

1. a) b) c) d) 2. a) b) c) d) +. a) b) c) d) e) ;. a) b) c) /. a)

SYSTE3 4OLTAGE < FRE=1ENCY. %hase to neutral and hase to hase s"stem !oltage and fre1uenc". <a,imum fluctuations of !oltage and fre1uenc" Ghether ower circuit or control circuit Bated im ulse withstand ca acit". EARTHING Solid (neutral) earthing Besistance Earthing (or #m edance) Earthed !ia ABC.su ression coils or similar #nsulated =eutral LOAD CAPACITY =ature of load C continuous, fluctuating or c"clic Loading of cable C for whole da" or art of it <a,imum !alue of load current Short tem erature o!erload and duration, if an" Antici ated future ca acities, if an" SHORT CIRC1IT CONDITIONS S"mmetrical short circuit current duration and ca acit" %ea5 short C circuit duration and ca acit". %hase to earth fault re1uirements. OPERATING CONDITIONS. &" e of #nstallation C in ground, in air, in ducts, channels, tunnels etc. 8ther s ecial locations li5e bridges, shafts, shi s or under water, should be considered indi!iduall". &his will decide whether unarmoured or armourd cable should be selected and the t" e of armouring C whether with flat stri s or round wires. =ormal ambient tem erature, ma,imum and minimum o erating tem erature Soil C &hermal resisti!it" E,ternal heat in ut, if an" Cable run C =o. of cables, grou ing, bends, routing etc.

b) c) d) e)

CABLES 11.11

6) a) b) c) H)

EN4IRON3ENTAL CONDITIONS =ormal tem erature and humidit", wet or dr" location etc. Altitude S ecial conditions li5e chemicals, oil, !ibrations. Bum s, harmful organism etc. 4OLTAGE - DROP 4oltage dro at full load should not e,ceed the statutor" limits.

D)

STANDARDISATION A cable with standard t" e and siAe of conductor should be referred. &his will enable in easier rocurement of cable and the accessories.

E)

F1T1RE PLANS #ncrease in load current due to future lans and e, ansion rogrammes should be ta5en into account while deciding the conductor siAe.

1).)

3ATCHING &he cable to be selected should match the associated e1ui ments li5e transformer and switch gear in erformance characteristics.

11)

STAT1TORY RESTRICTIONS2 A 5nowledge of statutor" restrictions for limited a lication of co conductor material is necessar". er as a

12) N

OTHER SPECIAL CONDITIONS> IF ANY2 @or e,am le, length of cable in single length, t" e of drum C wooden or metallic etc. -e ending u on the a lication of the cable, all or few of abo!e oints will come into icture while selecting a re1uired and most suitable cable. Ghile floating an en1uir" or lacing a urchase order, the following technical information regarding %4C insulated cable should be furnished to the su lier$.

1.

4oltage grade.

CABLES 11.12

2. +. ;. /. a) b) 6. a) b) c) H) D) E)

Conductor siAe and where a licable siAe of reduced neutral conductor. Conductor material C Aluminium or co er. =o of cores. &" e of inner sheath and material$ E,truded rubber or %4C . Gra ing of %4C ta es. Armouring $ Ghether armoured or unarmoured cable. @or multi core armoured cables, t" e of armouring material should be s ecified !iA. :al!anised round steel wire or flat steel stri . @or single core cables, non magnetic armouring material (generall" K*;L grade aluminium wires) should be s ecified.

&" e of outer sheath (%4C or @BLS %4C) . Beference to #ndian Standard . 8ther s ecial re1uirement, if an" e.g single length of cable in an indi!idual drum, t" e of drum C wooden or steel etc.

?OINTING AND TER3INATION OF CABLES Ste s ta5en for selection of 9ointing 5it. 1. 2. +. ;. Select the 9ointing 5it according to the siAe of the cable and t" e of 9oint i.e straight 9oint or end termination. Ghether the end termination is indoor or outdoor t" e. &" e of cable and t" e of 9ointing 5it to be chosen. <.seal?Ba"chem, #ns ect the 5it and its contents. 1. 2. +. ;. /. 6. H. D. E. Be1uired 1uantit" of 9ointing com ound (<.seal 9ointing 5it) *ardener %lastic mould <ould adhesi!e.cum.sol!ent <.seal fast setting utt" Earth continuit" connection (onl" for armoured cable) Self bonding insulating ta e S acers Co er binding wire

CABLES 11.1+

1). 11. 12. 1+. 1;. 1/. 16. 1H. 1D. 1E.

Semi conducting self bonding ta e (FL%E cables) %4C &a e #nstruction s5eet %4C Boot for (*& cables out door termination onl") Self bond #nsulating ta e (for outdoor cable end termination) Self Amalgamating silicon ta e #nsulators Crim ing t" e lugs ="lon string for FL%E cables Be1uired 1uantit" of Besin com . @or cast iron 5its.

CO3PARISION BET6EEN O4ERHEAD LINES AND CABLE 2nderground cables are used where 8!erhead lines are not ossible as in large cities des ite the fact that in their case, cost er 3G is much more as com ared to 8!er head transmission lines. Another ad!antage of o!er head s"stem for distributors is that ta ing can be made at an" time without an" disturbance which is of great im ortance in ra idl" de!elo ing areas. *owe!er, 2nderground cables are more ad!antageous for feeders which are not li5el" to be disturbed for ta ing ur oses because, being less liable to damage through storms or lighting or e!en damage, the" offer a safer guarantee of continuit" of su l". But this ad!antage ma" be offset b" the cost of trending and e, ensi!e 9ointing necessar" in case of re airs. *owe!er, cables score o!er o!erhead lines in case where !oltage regulation is more im ortant, because due to !er" small s acing of their conductors the" ha!e a !er" low inductance and hence low inducti!e dro s. <aintenance oint of !iew 1. 2. +. ;. /. 6. H. D. 8!er head lines re1uires eriodic ins ection 8!er head lines atrolling from the grounds for an" damage at the inter!als of + months. #ns ect the insulators, sag, earthing, cross arms an" missing of oles. #m ro er clearance, bro5en strands, loose or bro5en wins or ta es, clearance with other lines etc. &he trees which ha!e become dangerous for the lines and re1uire remo!al or trimming Bird nests coming on the o!er head lines Loose 9um ers %re!enti!e maintenance

CABLES 11.1;

E.

8!er head line maintenance is more and initial cost is low which as underground line maintenance is nearl" Aero but initial cost is more.

G1IDE LINE FOR 1NDERGRO1ND CABLES. 1. 2. +. ;. /. 6. H. D. E. 1). Sur!e" the route and ma5e a ro er lan on drawing so that ro er route will be decided. <ar5 the s ecified location on the drawing. Cable la"ing should be 1 mtr awa" from the road side. A trench of 1 mtr de th and )./ m wide is to be e,ca!ated for la"ing the underground cable. A channel is to be made for la"ing the cable b" channels. utting bric5s? cemented

La" the cables in between the bric5s?cemented channels and co!ered the cable with sand. Befill the e,ca!ated trench and ut cable mar5er on them at a distance of 2) mtrs. Alwa"s ut cable mar5er at the bends and also on the loo s. Alwa"s 5ee loo at the termination ends and in between the long length cables at a distance of 1)) mtrs. #f one or more cables ut in the same trench then bric5s should be ro!ided between each two cable? alternate cable. Cable mar5ers should ha!e following information L& cables and route mar5 i.e for L& cables and route mar5 i.e for L& cable. *& cable and route mar5 i.e for *.& cables. %ut the cable drum on the two 9ac5s so that it will mo!e freel". %ull the cable straight and laid in the trench. &here should not be an" twist or wrin5le in the cable length. Before and after la"ing the cable, megger it. <egger !alue should not be less than 1 mtr. @or L& cables at 1)))4 and for *& cable megger it with /34 megger. Also chec5 the continuit" and earth resistance of each core before la"ing the cable. Also megger the each core with other. <egger !alue should not be less than 1 < ohm.

11.

12. 1+. 1;.